Portable shirt collar stay manufacturing device and method

ABSTRACT

A method of manufacturing a collar stay including an elongated body and a pointed end includes receiving a stiff, solid material in a portable collar stay manufacturing device including a blade for cutting a collar stay; and cutting the stiff, solid material using the blade into the collar stay.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application 61/869,913 filed on Aug. 26, 2013 under 25 U.S.C. 119, and is incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates generally to collar stay manufacturing devices and methods, and specifically to portable collar stay manufacturing devices and methods.

BACKGROUND OF THE INVENTION

Shirt collar stays have been around for many years. The purpose of the collar stay is to keep the collar of a shirt straight. It is an essential part of a shirts appearance. Some shirts have built in collar stays but the problem with that concept is that collar stays are mostly made of plastic and they bend. Once a collar stay bends they are no longer useful and need to be replaced. Hence, most shirts, especially expensive, high-end shirts do not have built in collar stays. Most collar stays have a life span that is shorter than the life span of the shirt.

There are also metal collar stays that last the life span of the shirt but they are expensive and slip out of the collar stay placement slot because of the weight of the metal stay and the fine finish of the metal.

Collar stays are truly an essential part of any dress shirt. A dress shirt with a bent collar stay or without one period looks bad no matter how expensive the shirt. The collar stay gives the look of elegance. For this reason, every store that sells dress shirts also sells collar stays or in some stores they give them away free of charge. However, the collar stays that are given free of charge at some stores are usually of poor quality made of thin plastic. The life span of the thin collar stays are short and don't outlast the life of a dress shirt

There are no portable devices of any kind that make collar stays.

SUMMARY OF THE INVENTION

The present invention involves a portable collar stay manufacturing device that not only manufacturers collar stays, but gives new use to material such as plastic (e.g., plastic hotel cards) and paper that would otherwise be shredded or thrown away and not recycled.

One aspect of the invention is designed for a traveling person who may need to make a collar stay. In this aspect, the portable collar stay manufacturing device is a small, compact, light tool, akin to a nail clipper, that is easy to carry and use. A pressure part or lever of the portable collar stay manufacturing device enables the user to impart the pressure necessary to cut multiple collar stays at the same time with the durable material. The portable collar stay manufacturing device includes a bottom part including a sliding tray (where the collar stays are stored after they are made) that comes out. The bottom part has sharp blades with the design size of the collar stays. The collar stay blades have two different size blades making multiple (e.g., four) stays at a time of the same or different (e.g., two different sizes) sizes. The blades are part of removable blade inserts so that the user can place different blade configurations for making different size and/or configuration collar stays and also so that the blades can be replaced when the sharpness is lost after a long period of use. In use, the sturdy material used to make the collar stay is inserted into the device so that the sturdy material lays at the bottom part of the device on the blades. The top part of the device is the pressure part that will be used to push the sturdy material, via a top metal plate, against the blades that will cut and make the collar stays. Alternatively, the blades may be disposed on an underside of the top metal plate alternatively to, or in addition to, the blades being disposed on a top/upper side of the bottom metal plate. The user pushes the pressure lever down with the palm portion of one's hand, creating the pressure necessary to cut and form the collar stays.

Another aspect of the invention involves a small, compact, electric portable collar stay manufacturing device. In this aspect, the portable collar stay manufacturing device is easy to use and can be used with batteries or plug into an electric power socket. It only requires the operator to place a piece of sturdy material (e.g., plastic hotel card) into a designated slot and then the pushing of a button that activates a pressure lever that moves down, creating pressure, pushing the key material against blades at the bottom of the device, which perforate the sturdy material item into the shape and creation of collar stays.

In both of the above aspects of the invention, the portable collar stay manufacturing device is unique for several reasons, including the fact that it is both a collar stay maker and a storage device all built in one. The portable collar stay manufacturing device also has a storage device adapted to the bottom of the device that will house the collar stays. The portable collar stay manufacturing device has a removable blade insert so that the operator can cut multiple (e.g., four) different-size collar stays at once. By removing the removable blade insert and replacing it with a different removable blade insert, a user can make different size and/or configuration stays, multiple stays of the same size, multiple stays where at least some of the stays are of a different size and/or configuration.

The portable collar stay manufacturing device enables users, for the first time, to make collar stays (e.g., of any type of stiff, solid material including unused credit cards, hotel key cards, dvd's, file folders, business cards, sturdy brochures, sturdy paper, or other sturdy material other than metal) at home or while traveling. The portable collar stay manufacturing device allows people to recycle these type of materials where in the past they would be shredded or simply discarded. The portable collar stay manufacturing device not only creates different size collar stays, but additionally has a storage space at the bottom so that the collar stays can be stored after they are made by this device. This device enables one to make collar stays of many qualities and sizes.

A further aspect of the invention involves a method of manufacturing a collar stay including an elongated body and a pointed end. The method comprises receiving a stiff, solid material in a portable collar stay manufacturing device including a blade for cutting a collar stay; and cutting the stiff, solid material using the blade into the collar stay.

One or more implementations of the aspect of the invention described immediately above includes one or more of the following: the stiff, solid material is a plastic hotel key card; the portable collar stay manufacturing device is hand-holdable; the portable collar stay manufacturing device includes a first part and a second part, the blade is carried by one of the first part and the second part, and at least one of the first part and the second part is movable to impart pressure on the stiff, solid material to cause the blade to cut the stiff, solid material into the collar stay; the portable collar stay manufacturing device includes a blade insert that includes multiple blades to cut multiple collar stays, and the method includes cutting multiple collar stays from the stiff, solid material with the multiple blades of the blade insert; the multiple blades are configured to cut at least two different-sized and configuration collar stays; the multiple blades are configured to cut at least two collar stays of the same size and configuration; the multiple blades of the blade insert form a first blade configuration, and the method further includes replacing the blade insert with a different blade insert having multiple blades forming a second blade configuration different from the first blade configuration; the portable collar stay manufacturing device includes a storage device to store manufactured collar stays and the method further includes storing manufactured collar stays in the storage device; the method further includes removing stored manufactured collar stays from the storage device; the portable collar stay manufacturing device includes a mechanical coupling mechanism for imparting pressure to cut the collar stay with the blade; the portable collar stay manufacturing device further includes a pressure lever mechanism to assist in imparting pressure to cut the collar stay with the blade; and/or the portable collar stay manufacturing device includes an electro-mechanical coupling mechanism for imparting pressure to cut the collar stay with the blade.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings, which are incorporated in and form a part of this specification illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention.

FIG. 1 is a front elevational view of an embodiment of a portable mechanical collar stay manufacturing device.

FIG. 2 is a perspective view of a mold for the portable collar stay manufacturing device of FIG. 1.

FIG. 3 is a front elevational view of another embodiment of an electrical portable collar stay manufacturing device.

FIG. 4 is a front elevational view of a further embodiment of a portable mechanical collar stay manufacturing device.

FIG. 5 is a perspective view of a collar stay manufactured by the portable collar stay manufacturing device.

FIG. 6 is a perspective view of the bottom part of the portable collar stay manufacturing device, which receives the removable blade insert.

FIG. 7 is a top plan view of multiple embodiments of different removable blade inserts.

DESCRIPTION OF EMBODIMENT OF THE INVENTION

With reference to FIGS. 1-2, an embodiment of a portable mechanical collar stay manufacturing device 10 will be described. The portable mechanical collar stay manufacturing device 10 includes a first/bottom part or base 12 and a second/top part or pressure part 14 operable coupled together by a mechanical coupling mechanism 16.

The bottom part 12 has a substantially rectangular configuration and includes a slot 18 and a tray 20 slidably receivable in the slot 18. The tray 20 holds and stores collar stays 22 (FIG. 5). The collar stays 22 each include a flat elongated body 23 with a pointed end 25 and an opposite non-pointed (e.g., straight/flat, curved) end 27

With reference to FIGS. 2 and 6, an upper side 24 of the bottom part 12 includes a receiving section 26 that receives a removable blade insert 28. The removable blade insert 28 is one of a variety of different removable blade inserts 28 that may be inserted into and used with the portable mechanical collar stay manufacturing device 10. The blade insert 28 includes blades 30 in the configuration of the collar stays 22.

The top part 14 has a substantially rectangular configuration and includes an elongated substantially rectangular palm presser member 32 along an upper side 34 of the top part 14. An underside 36 of the top part 14 includes a top metal plate or section 38.

The mechanical coupling mechanism 16 operably couples the bottom part 12 and the top part 14 for imparting pressure on a durable material (e.g., plastic hotel card) disposed between the top metal section 38 of the top part 14 and the blades 30 of the bottom part 12 for cutting the collar stays 22. The mechanical coupling mechanism 16 includes circular springs that hold top part 14 and bottom part 12 separated from each other. A pair of metal pin rods or pins allow pivotal movement of the top part 14 and bottom part 12 of the device 10. The springs function to create the separation necessary so that the operator can insert the sturdy plastic material in between the top part 14 and the bottom part 12. Once the palm presser member 32 is pressed by the operator, the springs will constrict, allowing the top part 14 to press the durable plastic material against the blades 30.

To manufacture collar stays 22, a user inserts a durable material (e.g., plastic hotel card) over the blades 30 of the bottom part 12 and under the top metal section 38 of the top part 14. Then, the user presses down on the palm presser member 32 of the top part 14, imparting downward pressure by the top metal section 38 onto the durable material sandwiched between the blades 30 and the top metal section 38. This downward pressure onto the durable material causes the blades 30 to cut into the durable material, and form the collar stays 22. The tray 20 is pulled out from the lower part 12 and the collar stay(s) 22 are stored in the tray 20 for later use or the collar stay(s) are inserted into the stay pockets in the collar of the user's dress shirt.

With reference to FIG. 3, an embodiment of an electrical portable collar stay manufacturing device 40 will be described. Similar elements to those described above will be shown and/or described with the same reference number, but are shown with an “a” suffix. The electrical portable collar stay manufacturing device 40 is substantially similar to the mechanical portable collar stay manufacturing device 10, except that instead of a mechanical coupling mechanism 16, the electrical portable collar stay manufacturing device 40 includes an electro-mechanical coupling mechanism 42 for imparting pressure on a durable material (e.g., plastic hotel card) disposed between the top metal section 38 a of the first/top part 14 a and the blades 30 a of the second/bottom part 12 a for cutting the collar stays 22. The electro-mechanical coupling mechanism 42 includes an electric motor that causes the top part 14 a to impart pressure on the durable plastic material between the top part 14 a and the blades 30 a. Through a system of pressure gears located adjacent to the motor, the electric motor imparts the pressure necessary to cut the stays. The motor includes a circuit board that is attached to either an electric outlet cord or batteries located parallel to the top part 14 a.

Alternatively, the electro-mechanical coupling mechanism 42 may be a solenoid mechanism or other electro-mechanical mechanism that translates electrical energy into mechanical energy for imparting enough pressure onto the durable material sandwiched between the blades 30 a and the top metal section 38 a so that the downward pressure onto the durable material causes the blades 30 a to cut into the durable material, and form the collar stays 22. The electrical portable collar stay manufacturing device 40 may include one or more batteries (e.g., rechargeable batteries) and/or a power cord/plug that plugs into an electrical outlet for powering the electro-mechanical coupling mechanism 42. A button on the electrical portable collar stay manufacturing device 40 is operated by the user to actuate the electro-mechanical coupling mechanism 42.

To manufacture collar stays 22, a user inserts a durable material (e.g., plastic hotel card) over the blades 30 a of the bottom part 12 a and under the top metal section 38 a of the top part 14 a. Then, the user presses the button, which actuates the electro-mechanical coupling mechanism 42, causing sufficient downward pressure to be imparted onto the durable material sandwiched between the blades 30 a and the top metal section 38 a so that the downward pressure onto the durable material causes the blades 30 a to cut into the durable material, and form the collar stays 22. The tray 20 a is pulled out from the lower part 12 a and the collar stay(s) 22 are stored in the tray 20 a.

With reference to FIG. 4, another embodiment of a portable mechanical collar stay manufacturing device 50 will be described. Similar elements to those described above will be shown and/or described with the same reference number, but are shown with a “b” suffix. The portable mechanical collar stay manufacturing device 50 is substantially similar to the mechanical portable collar stay manufacturing device 10, except that the portable mechanical collar stay manufacturing device 50 includes a pressure lever mechanism 52 to enable the user to impart the pressure necessary to cut the multiple collar stays 22 from the durable material (e.g., plastic hotel card).

The pressure lever mechanism 52 includes a pressure lever 54 with a handle 56 at one end and a hook member 58 with a hook 60 at an opposite end. The pressure lever 54 is pivotally coupled to the first/top part 14 b via pivot mechanism 62. The top part 14 b is hingeably connected to the second/bottom part via a hinge mechanism 64. At an opposite end of the bottom part 12 b is a catch 66.

To manufacture collar stays 22 using the portable mechanical collar stay manufacturing device 50, a user inserts a durable material (e.g., plastic hotel card) over the blades 30 b of the bottom part 12 b and under the top metal section 38 b of the top part 14 b. Then, the user controls the pressure lever mechanism 52 to cause the hook 60 to hook under the catch 66. Then, user presses the handle 56 downward until the handle 56 is adjacent to upper side 34 b of the top part 14 b. The pressure imparted by the closing of the portable mechanical collar stay manufacturing device 50 via the pressure lever mechanism 52 onto the durable material sandwiched between the blades 30 b and the top metal section 38 b causes the blades 30 b to cut into the durable material, and form the collar stays 22. The tray 20 b is pulled out from the lower part 12 b and the collar stay(s) 22 are stored in the tray 20 b for later use or the collar stay(s) are inserted into the stay pockets in the collar of the user's dress shirt.

In alternative embodiments to those shown in FIGS. 1-6, the blades may be disposed on an underside of the top part alternatively to, or in addition to, the blades being disposed on a top/upper side of the bottom part.

With reference to FIG. 7, multiple embodiments of different removable blade inserts 70, 72, 74, 76 with different blade configurations are shown. The removable blade insert 70 includes blades 78, 80 forming a first blade configuration configured to cut two collar stays of a first size, shape, and configuration and two collar stays of a second, different size, shape, and configuration. The removable blade insert 72 includes blades 82 forming a second blade configuration configured to cut two collar stays of a third size, shape, and configuration. The removable blade insert 74 includes blades 84, 86 forming a third blade configuration configured to cut two collar stays of fourth size, shape, and configuration and two collar stays of a fifth, different size, shape, and configuration. The removable blade insert 72 includes blades 82 forming a fourth blade configuration configured to cut two collar stays of a sixth size, shape, and configuration. By removing the removable blade insert 28 and replacing it with a different removable blade insert 70, 72, 74, 76, a user can make different size and/or configuration stays, multiple stays of the same size, multiple stays where at least some of the stays are of a different size and/or configuration. The ability to make different size and/or configuration stays is important because different shirts/collars can require different size and/or configuration stays. Also, the size and/or configuration of collar stays may change over time depending on the fashion of the time. There were times in history and there is expected to be times in the future where collars were/are long, other times the popular collars were/are smaller, and other times were/are a size in between.

The portable collar stay manufacturing devices 10, 40, 50 not only allow the manufacture of collar stays at home or while traveling, but give new use to material such as plastic/paper (e.g., unused credit cards, hotel key cards, dvd's, file folders, business cards, sturdy brochures, sturdy paper, or other sturdy material other than metal) that would otherwise be shredded or thrown away and not recycled.

The above figures may depict exemplary configurations for the invention, which is done to aid in understanding the features and functionality that can be included in the invention. The invention is not restricted to the illustrated architectures or configurations, but can be implemented using a variety of alternative architectures and configurations. Additionally, although the invention is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features and functionality described in one or more of the individual embodiments with which they are described, but instead can be applied, alone or in some combination, to one or more of the other embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus the breadth and scope of the present invention, especially in the following claims, should not be limited by any of the above-described exemplary embodiments.

Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as mean “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; and adjectives such as “conventional,” “traditional,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. Furthermore, although item, elements or components of the disclosure may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. 

I claim:
 1. A method of manufacturing a collar stay including an elongated body and a pointed end, comprising: receiving a stiff, solid material in a portable collar stay manufacturing device including a blade for cutting a collar stay; cutting the stiff, solid material using the blade into the collar stay.
 2. The method of claim 1, wherein the stiff, solid material is a plastic hotel key card.
 3. The method of claim 1, wherein the portable collar stay manufacturing device is hand-holdable.
 4. The method of claim 1, wherein the portable collar stay manufacturing device includes a first part and a second part, the blade is carried by one of the first part and the second part, and at least one of the first part and the second part is movable to impart pressure on the stiff, solid material to cause the blade to cut the stiff, solid material into the collar stay.
 5. The method of claim 4, wherein the portable collar stay manufacturing device includes a blade insert that includes multiple blades to cut multiple collar stays, and the method includes cutting multiple collar stays from the stiff, solid material with the multiple blades of the blade insert.
 6. The method of claim 5, wherein the multiple blades are configured to cut at least two different-sized and configuration collar stays.
 7. The method of claim 5, wherein the multiple blades are configured to cut at least two collar stays of the same size and configuration.
 8. The method of claim 5, wherein the multiple blades of the blade insert form a first blade configuration, and the method further includes replacing the blade insert with a different blade insert having multiple blades forming a second blade configuration different from the first blade configuration.
 9. The method of claim 1, wherein the portable collar stay manufacturing device includes a storage device to store manufactured collar stays and the method further includes storing manufactured collar stays in the storage device.
 10. The method of claim 9, further including removing stored manufactured collar stays from the storage device.
 11. The method of claim 1, wherein the portable collar stay manufacturing device includes a mechanical coupling mechanism for imparting pressure to cut the collar stay with the blade.
 12. The method of claim 11, wherein the portable collar stay manufacturing device further includes a pressure lever mechanism to assist in imparting pressure to cut the collar stay with the blade.
 13. The method of claim 1, wherein the portable collar stay manufacturing device includes an electro-mechanical coupling mechanism for imparting pressure to cut the collar stay with the blade. 